IAME Parilla X30 125cc RL Overhaul Manual

28/09/05 MAN-044 /A

1

OVERHAUL MANUAL

28/09/05 MAN-044 /A

2

INDEX

Page

1. - PARILLA X30 125cc RL – TaG ENGINE DISASSEMBLY 1

2. - CRANKSHAFT DISASSEMBLY/ ASSEMBLY 10

2.1- CRANKSHAFT DISASSEMBLY 10

2.2- CRANKSHAFT ASSEMBLY 12

3. - PARILLA X30 125cc RL – TaG ENGINE ASSEMBLY 15

ATTACHMENTS

- FASTENER TORQUE VALUES

- CROSS PATTERN LOCKING ORDER ON CRANKCASE

- MAIN PRESCRIPTIONS

- CON-ROD BIG AND SMALL END BEARING TOLERANCES

- GEAR INSTALLATION - RECOMMENDATIONS

- LIST OF OVERHAUL TOOLS

- Table for wear evaluation on Bearings/ Halfcrankshafts

- BENCH ENGINE FIXING TOOL – Drawing

MAN-044/A

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1 – X30 125cc RL – TaG ENGINE DISASSEMBLY

OPERATIONS PICTURES

1.

DISCHARGE OIL FROM THE ENGINE

- UNSCREW THE OIL LEVEL PLUG

(see Fig.1).

(14mm socket wrench)

- TILT THE ENGINE TO DISCHARGE OIL

(see Fig.2).

2.

FIX THE ENGINE ON THE BENCH VICE

- SCREW ON N°2 SCREWS M8x60 ON THE

CRANKCASE

BENCH TOOL (see attached drawing )

3.

REMOVE THE EXHAUST HEADER

- UNSCREW N°2 NUTS M8 (see Fig. 3).

(13mm SOCKET WRENCH)

- REMOVE N°2 WASHERS

- REMOVE THE EXHAUST GASKET

Fi

g

.1

Fi

g

.2

Fig.3

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4.

REMOVE THE IGNITION

- REMOVE THE STATOR

UNSCREW N°4 ALLEN SCREWS M5x25 (see

Fig.4)

(4mm ALLEN WRENCH - T TYPE)

- REMOVE SPARKPLUG AND INSTALL THE

THE PISTON FITTING (P.N. 10271) TO

PREVENT THE CRANKSHAFT FROM

TURNING (see Fig.5).

- REMOVE THE NUT M10 AND WASHER

(see Fig.6).

(17mm SOCKET WRENCH)

- EXTRACT THE ROTOR (see Fig.7).

(USE A SCREWDRIVER IF NECESSARY)

REMOVE KEY FROM SHAFT

Fig.4

Fig.5

Fig.6

Fig.7

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5.

REMOVE THE GEAR BOX COVER

- UNSCREW N°7 ALLEN SCREWS M6x16

(see Fig.8).

(5mm ALLEN WRENCH - T TYPE)

- REMOVE COVER AND WASHER

(USE A PLASTIC MALLET IF NECESSARY)

(see Fig.9).

6.

REMOVE GEARS

- REMOVE RETAINING RINGS FROM THE

CRANKSHAFT AND BALANCE SHAFT

(see Fig.10).

(PLIERS FOR RETAINING RINGS)

- REMOVE GEAR ON THE CRANKSHAFT

(see Fig.11).

ATTENTION:

MARK THE GEAR FOR IDENTIFICATION

WHEN REASSEMBLING

NOTE:

IN THE ENGINES MNUFACTURED AFTER

SEPTEMBER ’05, THE FIXING OF THE GEAR

ON THE CRANKSHAFT IS MADE BY A

SPACER WITH AN “OR” WHICH IS PUSHED

AGAINST GEAR BY THE IGNITION ROTOR

(see drawing).

Fig.8

Fig.9

Fig.10

Fig.11

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- REMOVE GEAR FROM THE BALANCE

SHAFT

(see Fig.12).

(USE A SCREWDRIVER IF NECESSARY) .

7.

REMOVE ELECTRIC STARTER

- UNSCREW N°2 ALLEN SCREWS M6x35

(see Fig.13).

( 5mm ALLEN WRENCH – T TYPE )

- REMOVE STARTER (see Fig.14).

NOTE:

IN THE ENGINES MNUFACTURED AFTER

SEPTEMBER ’05, THE STARTER CAN ALSO

BE REMOVED WITHOUT TAKING AWAY

THE GEARS COVER BUT SIMPLY BY

REMOVING THE CLAMP OF THE COVER

(see drawing).

8.

REMOVE CLUTCH

- DISCONNECT THE GROUND CABLE FROM

THE CRANKCASE

UNSCREW THE ALLEN SCREW M6x12

(see Fig.15).

(5mm ALLEN WRENCH-T TYPE)

Fig.12

Fig.13

Fig.14

Fig.15

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- REMOVE CLUTCH COVER

UNSCREW N°3 ALLEN SCREWS M6x25

(see Fig. 16).

(5mm ALLEN WRENCH – T TYPE)

- REMOVE THE LOCKING NUT M10 FROM

CLUTCH DRUM (see Fig.17).

(17mm SOCKET WRENCH )

NOTE:

MAKE SURE THAT THE PISTON STOP TOOL

IS INSTALLED (P.N. 10271)

- REMOVE OUTER WASHER, CLUTCH

DRUM, ROLLER CAGE AND INNER

WASHER

- REMOVE THE PISTON STOP TOOL

AND WITH THE CLUTCH LOCKING

WRENCH (P.N. 10270), REMOVE THE

LOCKING NUT M20 FROM CLUTCH BODY

(see Fig.18).

( 30 mm HEXAGON RING WRENCH)

ATTENTION:

TURN CLOCKWISE AS NUT HAS LEFT

THREAD.

- REMOVE CLUTCH BODY AND STARTING

RING FROM THE CRANKSHAFT WITH THE

CLUTCH DISASSEMBLY TOOL

(P.N. 10272-C) (see Fig.19).

(12mm ALLEN WRENCH

(27mm WRENCH)

Fig.16

Fig.17

Fig.18

Fig.19

MAN-044/A

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- REMOVE STARTING RING

FROM CLUTCH BODY

UNSCREW N°3 SCREWS M6x12 (see

Fig.20).

(10mm SOCKET WRENCH)

9.

REMOVE STARTER COUNTERSHAFT

- REMOVE STARTER COUNTERSHAFT

COVER

UNSCREW N°3 ALLEN SCREWS M6x25 (see

Fig.21).

( 5mm ALLEN WRENCH – T TYPE )

- EXTRACT STARTER COUNTERSHAFT

(see Fig.22).

10.

REMOVE CARB. INLET CONVEYOR

- UNSCREW N°4 ALLEN SCREWS M6x25

(see Fig.23).

(5mm ALLEN WRENCH –T TYPE )

- REMOVE OUTER GASKET FROM

CONVEYOR

Fig.20

Fig.21

Fig.22

Fig.23

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- REMOVE REED GROUP

(see Fig.24).

- REMOVE INNER WASHER FROM

REED GROUP

11.

REMOVE CYLINDER HEAD

- UNLOOSE N°4 NUTS M8 BY HALF TURN

(CROSS PATTERN DISASSEMBLY),

REMOVE NUTS

(see Fig.25).

( 13mm HEXAGON RING WRENCH)

- REMOVE WASHERS

12.

REMOVE CYLINDER

(see Fig.26).

- REMOVE CYLINDER BASE GASKET

13.

REMOVE PISTON

- REMOVE CIRCLIPS FROM PISTON

(see Fig.27).

(SCREWDRIVER WITH ROUND EDGES)

ATTENTION:

DO NOT SCRATCH PISTON AND CIRCLIP

SEATS.

Fig.24

Fig.25

Fig.26

Fig.27

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- REMOVE PISTON PIN WITH SPECIAL

PISTON PUNCH (P.N. 10200)

(see Fig.28).

- REMOVE PISTON

- REMOVE ROLLER CAGE

14.

OPEN CRANKCASE

- UNSCREW N°10 ALLEN SCREWS M6x45

(see Fig.29).

(5mm ALLEN WRENCH – T TYPE)

- OPEN CRANKCASE WITH A PLASTIC

MALLET

(see Fig.30).

(PREVENT THE CRANKSHAFT FROM

FALLING)

15.

REMOVE CRANKSHAFT AND BALANCE

SHAFT

(see Fig.31).

Fig.28

Fig.29

Fig.30

Fig.31

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16.

REMOVE OIL SEALS

(USE A SCREWDRIVER) (see Fig.32).

17.

REMOVE BEARINGS (IF NECESSARY)

CHECK THE INNER DIAMETER OF

BEARINGS, ON DIFFERENT POINTS.

REFER TO THE ATTACHED TABLE TO

CHECK BEARING WEAR STATUS.

- REMOVE BEARINGS FROM CRANKSHAFT

WITH THE SPECIAL TOOL

(P.N. 10291) (see Fig.33).

REMOVE BEARING SPACERS

(0.10 / 0.15)

- REMOVE BALANCE SHAFT OUTER

BEARING (GEAR SIDE)

UNSCREW THE BEARING RETAINING

SCREW M5x10

(see Fig.34).

(4mm ALLEN WRENCH – T TYPE)

REMOVE BEARING WITH SPECIAL TOOL

(P.N. 10293)

(see Fig.35).

Fig.32

Fig.33

Fig.34

Fig.35

MAN-044/A

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- REMOVE INTERNAL BEARING FROM

BALANCE SHAFT

HEAT BEARING SEAT EXTERNALLY

WITH A BLOWPIPE

(see Fig.36).

ATTENTION:

CAREFULLY DEGREASE THE SURFACES

NEAR THE BEARING BEFORE HEATING

ONCE THE PROPER TEMPERATURE IS

REACHED, REMOVE BEARING KNOCKING

THE HALFCRANKCASE ON THE WORKING

BENCH.

2 – CRANKSHAFT ASSEMBLY/DISASSEMBLY

ATTENTION:

THE ASSEMBLY/DISASSEMBLY OPERATIONS ON THE ENGINE CRANKSHAFT, MUST BE

PERFORMED ONLY BY AN AUTHORIZED SERVICE CENTER USING THE SPECIALLY DESIGNED

TOOLS. USE OF UNFITTED TOOLS OR OPERATIONS PERFORMED BY UNSKILLED PERSONNEL

MAY DAMAGE THE CRANKSHAFT BEYOND REPAIR.

DESCRIPTION P.N.

CRANKSHAFT ASSEMBLY KIT 10110B-C

CRANKPIN BUSH (INCLUDED IN 10110B-C) 10150A

CRANKSHAFT DISASSEMBLY KIT INCLUDES: 10100A-C2

CRANKSHAFT SUPPORT 10100

CRANKSHAFT PLATE 10104A

CRANKSHAFT INSERT 10106

CRANKPIN PUSHER 10107

2.1 – CRANKSHAFT DISASSEMBLY

OPERATIONS PICTURES

1.

PLACE THE DISASSEMBLY TOOL

(P.N. 10100A-C2) UNDER THE PRESS

(PRESS 5 MeT).

2.

PLACE THE CRANSHAFT IN THE TOOL

BY INSERTING THE CRANKSHAFT PLATE

(P.N. 10104A) BETWEEN THE CRANKSHAFT

HALVES (see Fig.1).

Fi

g

.1

Fig.36

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3.

INSERT THE CRANKSHAFT INSERT

(P.N. 10106) AND USING THE CRANKPIN

PUSHER ( P.N. 10107 ) PRESS THE

CRANKPIN OUT

(vedi Fig.2).

4.

DISASSEMBLE THE COMPLETE CON-ROD

WITH WASHERS.

REPEAT THE OPERATIONS TO EXTRACT

THE CRANKPIN FROM THE OTHER HALF

CRANKSHAFT (see Fig.3).

BEFORE REASSEMBLING, WASH ALL PARTS WITH KEROSENE

a) CHECK STATUS OF CON-ROD (TOP

AND BOTTOM).

IF OVALIZATION EXCEEDS 0.01mm,

REPLACE CON-ROD.

- O.O1 CENTESIMAL MICROMETER (21/50)

- 0.001 BORE GAUGE WITH CHECK RING Ø26 AND Ø18

b) CHECK STATUS OF CRANKPIN

VISUAL CHECK – REPLACE IF

NECESSARY

REPLACE AFTER 30 WORKING HRS.

c) CHECK STATUS OF CAGE (BIG END)

VISUAL CHECK – REPLACE IF

NECESSARY

REPLACE AFTER 30 WORKING HRS.

d) CHECK STATUS OF CRANKSHAFT

HALVES.

CHECK BEARING SEATS IN

DIFFERENT POINTS.

REFER TO THE ATTACHED TABLE TO

CHECK THE WEAR STATUS OF THE

CRANKSHAFT HALVES.

e) CHECK STATUS OF SILVER SHIMS

VISUAL CHECK – REPLACE IF

NECESSARY .

FOLLOW ATTACHED TABLE FOR MAX. MATCHING PLAY

Fi

g

.2

Fi

g

.3

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2.2 – CRANKSHAFT ASSEMBLY OPERATIONS

OPERATIONS PICTURES

1. PLACE THE CRANKSHAFT ASSEMBLY

TOOL (P.N. 10110B-C) UNDER THE PRESS,

VERTICALLY (PRESS 5 MeT).

2. PLACE THE CRANKSHAFT TOOL INTO THE

ASSEMBLY TOOL.

3. OIL CRANKPIN HOLE ON CRANKSHAFT

HALF.

4.

PLACE CRANKPIN WITH CRANKPIN BUSH

(P.N. 10150A) ON CRANKSHAFT HALF (see

Fig.1).

5.

BRING UPPER PLATE OF TOOL IN

CONTACT WITH CRANKPIN (see Fig.2).

6.

PROGRESSIVELY PRESS UNTIL CRANKPIN

IS COMPLETELY DRIVEN IN

(see Fig.3).

Fi

g

.1

Fi

g

.2

Fi

g

.3

MAN-044/A

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7.

EXTRACT BUSH FROM CRANKPIN AND

PUT TOOL IN HORIZONTAL POSITION

(see.Fig.4).

8.

OIL CRANKPIN AND INSTALL:

-SILVER SHIM

-CON-ROD WITH ROLLER CAGE

-SILVER SHIM

(see Fig.5).

ATTENTION:

ROLLERS ARE FREE IN THE CAGE.

PREVENT THEM FROM FALLING,

WHEN INSERTING THE CAGE ON THE

CRANKPIN.

9.

PLACE THE SECOND CRANKSHAFT IN

THE SEAT OF THE COUNTERPLATE

(see Fig.6).

10.

BRING THE 2 PLATES CLOSE UNTIL THE

TOOL IS HAND PRESSED

(see Fig.7).

Fi

g

.4

Fi

g

.5

Fi

g

.6

Fi

g

.7

MAN-044/A

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11. OIL CRANKPIN AND CRANKPIN HOLE ON

CRANKSHAFT HALF.

12.

PUT TOOL IN VERTICAL POSITION (see

Fig.8).

13. PROGRESSIVELY PRESS THE TWO

CRANKSHAFT HALVES TOGETHER.

14. OPEN THE TOOL, PUT IT IN HORIZONTAL

POSITION AND EXTRACT CRANKSHAFT.

15.

CHECK THE AXIAL PLAY OF THE CON-ROD

(see Fig. 9).

IT MUST BE MIN. 0.3mm / MAX. 0.7mm.

IF PLAY IS HIGHER OR LOWER, REBUILD

THE CRANKSHAFT.

AFTER ASSEMBLING THE CRANKSHAFT, IT MUST BE ALIGNED. OTHERWISE EXCESSIVE

VIBRATIONS, HARD STARTING OR POOR ACCELERATION WILL RESULT.

a.

PLACE THE CRANKSHAFT BETWEEN THE

CENTERS, WITH DIAL INDICATORS

READING ON FRONT AND REAR BEARING

JOURNALS

(see Fig.10).

(CENTERS WITH CENTESIMAL DIAL

GAUGES AND COPPER HAMMER FOR

ALIGNMENT).

Fi

g

.8

Fi

g

.9

Fi

g

.10

MAN-044/A

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b. ROTATE CRANKSHAFT AND LOOK AT

DEFLECTION OF GAUGE NEEDLES

THE DEFLECTION MUST BE, AFTER

CENTERING, MAX. 0.01mm

(see drawing).

c.

ADJUST ALIGNMENT WITH A COPPER

HAMMER, IF NECESSARY

(see Fig.11).

3 –X30 125cc RL – TaG ENGINE ASSEMBLY

BEFORE REASSEMBLING, WASH ALL PARTS WITH KEROSENE

OPERATIONS PICTURES

1.

INSTALLING BEARINGS

- PLACE THE CRANKCASE HALVES UNDER

THE PRESS.

- INSERT BEARING SHIMS

(AVAILABLE SIZES 0.10 / 0.15 / 0.20)

(see Fig.1).

Fi

g

.11

Fi

g

.1

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- INSERT CRANKSHAFT BEARINGS; BALLS

TO BE ON UPPER SIDE VISIBLE DURING THE

ASSEMBLY

(see Fig. 2).

OIL BEARINGS AND BEARING SEATS

OUTSIDE.

USE TOOL TO INSERT THE BEARINGS

(P.N. 10290)

(see Fig.3).

- INSTALL INNER BALANCE SHAFT

BEARING; BEARING BALLS TO BE ON

UPPER SIDE.

(OIL BEARING BALLS BEFORE

INSTALLATION) .

OIL BEARINGS AND HALFCRANKCASE

SEATS.

USE THE SPECIAL TOOL TO ASSEMBLE

(P.N. 10292) BEARINGS

(see Fig.4).

- INSTALL OUTER BALANCE SHAFT

BEARING (GEAR SIDE); BEARING BALLS

TO BE ON UPPER SIDE.

OIL BEARINGS AND HALFCRANKCASE

SEATS .

USE SPECIAL TOOL (P.N. 10293)

TO INSERT BEARING (see Fig.5).

Fi

g

.5

Fi

g

.2

Fi

g

.3

Fi

g

.4

Fi

g

.5

MAN-044/A

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- INSTALL THE BEARING RETAINING.

SCREW M5x10 (see Fig.6). Allen.

TORQUE AT A 6 ÷ 8 Nm (50 ÷ 70 in-lb).

(4mm ALLEN WRENCH – T TYPE)

2.

CRANKCASE ASSEMBLY

- INSERT CRANKSHAFT AFTER OILING THE

CRANKSHAFT SEAT IN THE CRANKCASE

AND THE BEARING BALLS.

THE CRANKSHAFT MUST BE IN SAME

POSITION AS IN ORIGINAL INSTALLATION

(see Fig.7).

- ASSEMBLE CRANKCASE HALVES

N°10 ALLEN SCREWS M6x45 (see Fig.8).

(CROSS PATTERN ASSEMBLY – SEE

ATTACHED DRAWING).

TORQUE AT 8÷10 Nm (70 ÷ 90 in-lb)

(5mm ALLEN WRENCH – T TYPE)

ATTENTION:

AS FIRST STEP ASSEMBLE CRANKCASE

WITH 4 SCREWS AND CHECK CRANKSHAFT

AXIAL PLAY TO BE 0.20 ±0.05mm.

IF PLAY IS LOWER OR HIGHER

DISASSEMBLE CRANKCASE, EXTRACT

BEARINGS AND USE DIFFERENT STEEL

SHIMS (0.10/0.15/0.20) TO RECOVER PLAY.

SHIMS MUST BE EQUALLY POSITIONED (see

Fig. 9).

Fi

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.6

Fi

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.7

Fi

g

.8

Fi

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.9

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BEFORE FINAL ASSEMBLING OF

CRANKCASE HALVES APPLY FLUID GASKET

(Motorseal or equivalent) ON CRANKCASE

HALVES.

CLEAN EVENTUAL EXCESS OF PRODUCT

(see Fig.10).

- OIL CRANKSHAFT AND BEARING BALLS

SEATS BEFORE ASSEMBLING.

(see Fig.11).

- INSERT THE CRANKSHAFT AND BALANCE

SHAFT.

CLOSE THE CRANKCASE HALVES

(see Fig.12).

3.

INSTALLING SEALS

- APPLY SPECIAL LUBRICANT ON SEAL LIPS

(see Fig.13).

ATTENTION:

WHEN INSTALLING NEW SEALS, TURNING

THE CRANKSHAFT SHOULD RESULT MORE

DIFFICULT, BUT THIS IS NORMAL.

Fi

g

.13

Fi

g

.10

Fi

g

.11

Fi

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.12

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IAME Parilla X30 125cc RL Overhaul Manual

IAME Parilla X30 125cc RL Overhaul Manual

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